Ultrasonic Scan Coordinate Mapping for 3D Part Inspection
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Solution Overview
Problem
Current methods for translating test data from a testing environment to an end item coordinate system, particularly for ultrasonic scan data, are inefficient and inaccurate, especially when dealing with three-dimensional parts, as they rely on two-dimensional pixel data mapping.
Innovation Solution
A method and system that utilize a robot with an ultrasonic scanning device, controlled by a robot computing system, to acquire and translate scan data by aligning robot location information to end item location information using common reference points and electronic design models, enabling accurate translation from a robot coordinate system to an end item coordinate system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two-dimensional pixel data mapping is used to translate test data, then the process is simpler to implement, but the accuracy and efficiency of translating test data to end item coordinate system deteriorates
Solution Approach 1:
The patent transitions from two-dimensional pixel data mapping to three-dimensional coordinate system translation. By using at least three common reference points to establish a transformation matrix between the robot coordinate system and the end item coordinate system, the method achieves accurate three-dimensional spatial translation of ultrasonic scan data, resolving the limitation of 2D mapping for 3D parts.
Solution Approach 2:
The patent introduces common reference points as intermediaries to bridge the robot coordinate system and the end item coordinate system. These reference points serve as transformation anchors that enable accurate translation of test data locations from the robot's coordinate frame to the end item's coordinate frame, improving both accuracy and efficiency.
2Measurement precision
If robot coordinate system translation is implemented, then translation accuracy improves, but device complexity increases
Solution Approach 1:
The robot computing system performs multiple functions: controlling robot movement, acquiring ultrasonic scan data, recording robot location information, and translating coordinates to the end item coordinate system. By consolidating these functions into a single multi-functional system, the patent reduces overall device complexity while maintaining high translation accuracy.
Solution Approach 2:
The robot system autonomously performs coordinate translation using its own recorded location information and the common reference points. The system self-calibrates and transforms data without requiring external intervention, reducing operational complexity while ensuring accurate translation.
3Productivity
If three-dimensional coordinate translation is used, then translation efficiency improves, but the complexity of data processing increases
Solution Approach 1:
The patent performs preliminary actions by pre-establishing the transformation matrix using at least three common reference points before actual data translation occurs. This pre-computation of coordinate transformation parameters enables efficient real-time translation of test data without complex processing during the measurement phase, improving productivity while managing processing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for precise association of test data with end item coordinate systems, enhancing the accuracy and efficiency of non-destructive inspection processes, particularly for composite materials in aircraft parts, by integrating scan data into electronic design models.
Implementation Method 1
acquiring scan data during a plurality of scans of at least a portion of the part of an end item along a predetermined path plan using an ultrasonic scanning device
Data Source
AI summary
A method for associating test data for a part under test with an end item coordinate system includes acquiring scan data during a plurality of scans of at least a portion of the part of an end item along a predetermined path plan using an ultrasonic scanning device of a robot. Robot location information associated with the scan data acquired during the plurality of scans is recorded. The robot location information is based on a robot coordinate system. The robot location information is translated to end item location information within the end item coordinate system based on at least three common reference points in the predetermined path plan, an electronic design model of the end item within the end item coordinate system, and the part. A non-destructive inspection (NDI) system for associating the test data with the end item coordinate system is also provided.